Visible laser welding of electronic packaging, automotive electrics, battery and other components

Abstract

A visible light laser system and operation for welding materials together. A blue laser system and operation for welding conductive elements, and in particular thin conductive elements, together for use in energy storage devices, such as battery packs.

The invention claimed is: 
     
       1. A method of joining two metal components, using a blue laser beam, the method comprising:
 a. providing a source of a blue laser beam having a predetermined wavelength to a target location, the target location including a first component to be joined and a second component to be joined; 
 b. providing a scanning device and focusing optics configured to deliver the blue laser beam in a pattern and at a predetermined laser intensity to the target location, wherein the predetermined laser intensity defines a laser beam energy; 
 c. the blue laser beam and at least one of the first or second components having an absorptivity that is at least about 45%; 
 d. delivering the blue laser beam in the pattern and the predetermined laser intensity to the target location to weld the first and second components together; thereby forming a weld between the first and second components; wherein at least 45% of the laser beam energy is utilized to form the weld; and, 
 e. wherein the weld has a resistivity of about 0.1 mΩ to about 250 mΩ. 
 
     
     
       2. The method of  claim 1 , wherein the resistivity is from about 0.1 mΩ to about 200 mΩ. 
     
     
       3. The method of  claim 1 , wherein the resistivity is less than about 150 mΩ. 
     
     
       4. The method of  claim 1 , wherein the resistivity is less than about 100 mΩ. 
     
     
       5. The method of  claim 1 , wherein the resistivity is less than about 10 mΩ. 
     
     
       6. The method of  claim 1 , wherein the resistivity is less than about 1 mΩ. 
     
     
       7. The method of  claim 1 , wherein the scanning device moves the laser beam. 
     
     
       8. The method of  claim 1 , wherein the scanning device moves the first and second components. 
     
     
       9. The method of  claim 1 , wherein the power per area of the laser beam at the spot on the first, the second, or both components is less than about 1,000,000 W/cm 2 . 
     
     
       10. The method of  claim 1 , wherein the power per area of the laser beam at the spot on the first, the second, or both components is less than about 500,000 W/cm 2 . 
     
     
       11. The method of  claim 1 , wherein the power per area of the laser beam at the spot on the first, the second, or both components is less than about 100,000 W/cm 2 . 
     
     
       12. The method of  claim 1 , wherein the power per area of the laser beam at the spot on the first, the second or both components is less than about 50,000 W/cm 2 . 
     
     
       13. The method of  claims 1, 5, 6, 8, 9 or 10 , wherein the wavelength is about 450 nm. 
     
     
       14. The method of  claim 1 , wherein the first component and the second component are different metals. 
     
     
       15. The method of  claim 1 , wherein the first component and the second component are the same metal. 
     
     
       16. The method of  claim 1 , wherein the first component is selected from the group consisting of gold, copper, silver, aluminum, steel, stainless steel, and alloys of one or more of those metals. 
     
     
       17. A method of joining two metal components, using a blue laser beam, wherein the laser intensity at a weld site does not need to be appreciably changed, the method comprising:
 a. providing a source of a blue laser beam having a predetermined wavelength to a weld site, the weld site including a first component to be joined and a second component to be joined; 
 b. providing a scanner and a focusing optics in optical association with the source of the blue laser beam; 
 c. the source of the blue laser beam, the scanner and the focusing optics delivering the blue laser beam in a pattern and at a predetermined laser intensity to the weld site including the first and the second components; thereby welding the first and second components together, thereby forming a weld between the first and second components; wherein the predetermined laser intensity defines a laser beam energy; 
 d. wherein the blue laser beam consists essentially of the predetermined laser intensity from a start of the welding through a completion of the welding; and, 
 e. wherein at least 45% of the blue laser beam energy is utilized to form the weld. 
 
     
     
       18. The method of  claim 17 , wherein about 50% of the laser beam energy is utilized to form the weld. 
     
     
       19. The method of  claim 17 , wherein about 60% of the laser beam energy is utilized to form the weld. 
     
     
       20. The method of  claim 17 , wherein about 65% of the laser beam energy is utilized to form the weld. 
     
     
       21. The method of  claim 17 , wherein during the welding of the components the laser beam intensity is capable of varying from about 1% to about 20% during the welding. 
     
     
       22. The method of  claim 17 , wherein during the welding of the components the laser beam intensity is capable of varying about 10% during the welding. 
     
     
       23. The method of  claim 17 , wherein during the welding of the components the laser beam intensity is capable of varying form about 1% to about 5% during the welding. 
     
     
       24. The method of  claim 17 , wherein during the welding of the components the laser beam intensity is capable of varying about 1% during the welding.